Method of forming a structural element

ABSTRACT

A method of forming a structural element comprising feeding a continuous strip of material through a series of forming rolls to progressively bend the elongated strip into a desired transverse configuration. Insulating material is applied to the material as it is being formed. The continuous strip of material is notched to provide longitudinally spaced transverse grooves in the strip prior to forming and is severed at the grooves after the strip has been formed into the desired shape.

United States tat [151 3,638,465

Lickliter et al. 1 1 Feb. 1, 1972 [54] METHOD OF FORMING A [56]References Cited STRUCTURAL ELEMENT UNITED STATES PATENTS [72]figfigigfi ifilig fy fliiiggg :5 2,115,441 4/193 Black ..29/|ss ux of NY 2,127,618 8/1938 Riemenschneider ..29/4l7 2,447,694 8/1948 Finch..52/497 X [73] Assignee: Flangeklamp Corporation, Buffalo, N.Y.2,467,558 4/ 1949 Kapnek ,.52/690 X [22] Filed: 1969 PrimaryExaminer-Charlie T. Moon [21] Appl. No.: 805,542 Attorney-Christel 8LBean Related US. Application Data 57 ABSTRACT Continuation-impart of No.777,438, N0 v- A method of forming a structural element comprisingfeeding 1968 3,537,222 which ls a commuatlon'm' a continuous strip ofmaterial through a series of forming rolls P of 9 1963, to progressivelybend the elongated strip into a desired trans- 3,537,217' verseconfiguration. insulating material is applied to the material as it isbeing formed. The continuous strip of material [52] US. Cl ..72/ 181 isnotched to provide longitudinally Spaced transverse grooves [5 in thetri rior to fo ing and is evered at the grooves after [58] Field ofSearch ..29/155, 417, 41 1; 72/366, 234, the Strip has been f d into thedesired sham;

5 Claims, 20 Drawing Figures PATENTED FEB l 1972 SHEEY 1 OF 4PAIENTEDFEB H972 ale-38.465

SHEEI 2 [If 4 INVEN'I'ORS 205.507 1? L/CkL/TE'R 4121. 435017 BY JOHNEREEVES ATTORNEYS sic-538x65 PATENTED FEB. 1 I972 SHEEI 3 BF 4 INVENTORSROBERT E Z/CKL/TER EARL ABBOTT A TTORNE 5 METHOD OF FORMING A STRUCTURALELEMENT CROSS-REFERENCE TO RELATED APPLICATIONS This application is acontinuation-in-part of our pending application Christel & Bean Ser. No.777,438 filed Nov. 20, I968, now US. Pat. No. 3,537,222 for WallStructure, which application is a continuation-in-part of ourapplication Ser. No. 703,955 filed Feb. 8, I968, now US. Pat. No.3,537,217, for Wall Structures.

BACKGROUND OF THE INVENTION The present invention relates to a method offorming a structural element and, more particularly, to a method offorming an insulated sheet metal panel connector employed in theconstruction art.

In the construction field, it is known to employ various prefabricatedmodular wall and ceiling paneling arrangements for erecting wall, floor,and ceiling structures which can be readily installed and easilydismantled. Pending application Ser. No. 703,955 discloses structureswhich utilize sheet material panel connectors to provide a quicklyassembled supporting framework on which wall and/or ceiling panelstogether with door and window frame assemblies can be readily snapfitted in place.

It has been found desirable to mass-produce these panel connectors froma supply of continuous stock by forming the material into the desiredtraverse configuration and then cutting such formed element intopredetermined lengths. The cutting action deforms the shape of the endportions of the finished product and also produces irregular and jaggededges.

Tests are conducted on building structures to determine the rate of heattransfer in a given amount of time, and they are fire rated" inaccordance with their ability to resist heat transfer. Panel connectorsfonned of metal present a problem because they conduct heat. ApplicationSer. No. 777,438 discloses insulated panel connectors, and thisapplication is concerned with a method for continuous forming thereof.

SUMMARY OF THE INVENTION Accordingly, it is an object of the presentinvention to pro vide a method of forming metallic structural elementspossessing insulating means for minimizing the transmission of heattherethrough.

It is another object of this invention to provide a method of forming aninsulated structural element by progressively bending a flat strip ofmaterial into the desired transverse shape while simultaneously applyinginsulation thereto.

It is still another object of the present invention to provide a methodof forming a structural element by progressively bending a continuousflat strip of material transversely into the desired configuration andsevering the elongated formed strip into discrete elements havingsmooth, flat, opposite ends.

In carrying out this invention, a continuous strip of metal is advancedthrough a series of forming rolls to progressively form the elongatedstrip into a desired transverse configuration. As the forming operationtakes place, insulating material is applied to and deposited within theconfines of the outer walls of the partially formed strip to become apermanent component of the finished product. Prior to the formingoperation, the strip of metal is notched to provide longitudinallyspaced transverse grooves in the strip so that at the completion of theforming operation, the continuous length of formed strip can be clearlysevered at the grooves into predetermined lengths of finished elementshaving unbent, smooth, flat, opposite ends.

The foregoing and other objects, advantages and characterizing featuresof this invention will become clearly apparent from the ensuing detaileddescription of an illustrative embodiment thereof, taken together withthe accompanying drawings wherein like reference numerals denote likeparts throughout the various views.

DESCRIPTION OF THE DRAWING FIGURES FIG. 1 is a fragmentary, perspectiveview ofa structural element of continuous length formed by the method ofthe present invention;

FIG. 2 is a fragmentary, perspective view of a strip of material ofwhich the element is formed showing a transverse groove notched therein;

FIG. 3 is a fragmentary, perspective view of the insulating materialused to form a part of the finished structural element;

FIG. 4 is a diagrammatic side-elevational view of the apparatus forperforming this invention;

FIGS. 5-19 are end-elevational views of the structural element of FIG. 1illustrating various stages of the transverse configuration of theelement as it is being formed; and

FIG. 20 is an end-elevational view of the structural element formed bythe method of this invention.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT Referring now indetail to the drawings, there is shown in FIG. 1 an illustrativeembodiment of a panel connector strip, generally designated 22, formedby the process of this invention. Panel connector strip 22 comprises asheet metal fabrication of a unitary, one-piece construction formed toprovide a rectangular body portion having front face portions 24 and arear face 26 jointed and spaced apart by opposite side faces 28. A pairof flange portions 30 extend outwardly from front face portions 24 awayfrom rear face 26 to form a pair of corners adapted to receive the edgeportions of adjacent wall panel members for example. The metal or othersheet material of which panel connector 22 is fabricated is folded overat the outer end of flange portions 30 to provide cam surfaces 32leading to opposed shoulder portions 34, the opposite edges of the sheetmaterial retreating and terminating within the opening between flangeportions 30. Rear face 26 is provided with a restricted inlet opening 36having diverging sidewalls 38 to form a channel 37 within rectangularbody portion 24-28. A heat-insulating material 39, such as fiberglass orsubstantially pure braided asbestos for example, is disposed within therectangular body portion 2428 and partially between opposed flangeportions 30 behind channel 37 of panel connector 22 along the entirelength thereof to minimize thermal conduction of the connector.

Referring to the diagrammatic view of FIG. 4, an elongated flat strip ofmetal 40 (FIG. 5) of the desired width and gauge is continuouslyadvanced longitudinally and subjected to a plurality of operationsincluding fonning transverser notches or grooves in the strip atlongitudinally spaced intervals, shaping the strip into the desiredconfiguration while applying a heatinsulating material thereto, andsevering the formed continuous strip at said notches into discretelengths as will be described below.

As strip 40 is advanced, it passes through means at station A includinga flying tool couple having a backup plate 42 and a notching punch 44which is actuated downwardly at predetermined time intervals. Thecutting edge of punch 44 acts against the upper surface of strip 40 toscore or notch said upper surface and provide longitudinally spacedgrooves 46 (FIG. 2) in strip 40.

A significant feature of this invention is that punch 44 forms arelatively deep cut in strip 40 so that it may be readily severed at theend of its run after it has been formed to its final shape. It should benoted, however, that the transverse grooves 46 in strip 40 will in nomanner impede or restrict the subsequent forming operation that takesplace.

After the continuously advancing work leaves station A, it passesthrough a plurality of sets of horizontally disposed forming rolls 5052and vertically disposed forming rolls 54. Although each set of formingrolls 50, 52 and 54 differ in configuration at successive stations, theyhave been indicated by identical reference characters for ease ofdescription. The

pressure of these forming rolls 50-52 and 54 upon strip 40 and thestructural element being formed also serves to feed the strip forwardly.FIGS. 5-19 illustrate progressive stages of the forming of strip 40 intoa structural element as it advances through successive forming rollsuntil it reaches its final shape as shown in FIG. 20.

As shown in FIG. 6, a loop 60 is formed midway of the width of strip 40,hereinafter referred to as a structural element, by the first set offorming rolls 50, 52 and is progressively bent to form opposite walls 62in loop 60 and angular portions 64 (FIG. 7) extending outwardly from thelegs of loop 60. Next, element 40 passes through vertically disposedrollers 54 which form a necked portion 66 in loop 60 (FIG. 8).Thereafter, the top of loop 60 is slightly flattened as at 68 (FIG. 9)and generally horizontal portions 70 are formed laterally outwardly ofangular portions 64. The other ends of portions 70 are connected toupwardly inclined portions 72 which terminate in reverse-curved portions74. In the next progressive step (FIG. 10) notches 76 are formed atopposite sides of portions 70 and portions 72 are bent to form aninverted V-shape having leg portions 78 and 80 while the top of loop 60is completely flattened to form channel 37. Also, angular portions 82are formed between portions 72 and curved portions 74.

FIG 1 1 illustrates the next forming step whereby vertically disposedrolls 54 acting on opposite sides of strip 40 bend portions 82 inwardlytoward each other. Thereafter, the entire width of element 40 isprogressively bent inwardly as shown in FIGS. 12, 13 and 14 untilportions 82 have been bent to form the cam surfaces 32 and shoulders 34shown in the finished element of FIGS. ,1 and 20. In this stage of theforming operation, a continuous strip of insulating material 39 isapplied to element 40 and is deposited between portions 80 which are noworiented upwardly substantially parallel to each other to define apocket (FIG. 14). As shown in FIG. 4, the strip of insulating material39 is supplied from a reel 86 and is placed within the walls of thepartially formed element 40.

In the next succeeding forming operations, as shown in FIGS. 15 and 16,portions 80 are further bent inwardly about insulating material 39. Thepartially shaped element is then passed through a series of formingrolls 54 as depicted in FIGS. l7, l8 and 19 to shape the element in itsfinal form as shown in FIG. 20 wherein a portion of the insulatingmaterial 39 is confined within rectangular body portion 24-28 and aportion is disposed behind channel 37 between flange portions 30.

Upon completion of the final forming operation, the advancing structuralelement passes through a shearing station B comprising a flying cuttingmechanism having an upper cutting tool 90 which acts against the edge ofa lower cutting tool 92 to sever continuous element 40 into discretestructural elements of predetermined length. The cutting mechanism istimed with the rate of feed continuous element 40 to sever the same atthe grooves 46 earlier formed by the notching mechanism at station A. Ashereinafter mentioned, grooves 46 were deeply cut into strip 40 so thatthe cutting mechanism is not required to penetrate or cut through theentire thickness of the sheet material, but rather only a fractionthereof to clearly sever or break off a given length of formed elementfrom the continuous length thereof with a smooth, flat edge. Were thecutting edge of tool required to penetrate the entire thickness of thecontinuous formed element, the cutting action would produce irregularand jagged edges at the end portions of the finished element. Moreover,since the element is now formed into its final shape, the end portionsof the severed element would tend to be deformedor bent inwardly by thecutting tool. The method of the present invention eliminates the abovedeficiencies by notching the material when in a flat strip form tosufficiently weaken the same so that the formed element can be readilysevered at the notched grooves producing smooth, flat edges.

From the foregoing, it is apparent that the objects of the presentinvention have been fully accomplished. As a result of this invention,an improved method for forming a structural element is provided in whicha flat strip of material is notched prior to forming and subsequentlysevered after the forming operation to produce burr-free, smooth, flatedges. Also, heatinsulating material is applied to the element as it isbeing formed to produce a rigid, fire-rated structural elementpossessing the requisite stability and strength for use in constructionwalls and ceilings.

A preferred embodiment of this invention having been described andillustrated, it is to be understood that this has been done by way ofillustration only.

We claim:

1. A method of forming an elongated structural element comprisingfeeding a continuous strip of sheet material in a longitudinal path ofmovement, progressively bending said strip inwardly from the sidesthereof to form a continuous length of structural element having a bodyportion of generally rectangular cross section comprising a pair ofgenerally parallel front and rear faces connected by side faces, and apair of generally parallel flanges extending outwardly from said frontface away from said rear face.

2. The method of claim I wherein said strip also is formed to provide achannel having'a restricted inlet opening disposed within said bodyportion.

3. A method according to claim I including notching transverse groovesin said continuous strip of sheet material at predeterminedlongitudinally spaced intervals therealong prior to bending said strip,and severing said continuous length of structural element after formingthe same at said grooves into discrete structural elements.

4. A method of forming an elongated structural element comprisingfeeding a continuous strip of sheet material in a longitudinal path ofmovement, progressively bending said strip inwardly from the sidesthereof to form a continuous length of structural element having a bodyportion of generally rectangular cross section comprising a pair ofgenerally parallel front and rear faces connected by side faces, and apair of generally parallel laterally spaced flanges extending outwardlyfrom said front face away from said rear face, said flanges being foldedover at the outer ends thereof to provide cam surfaces leading toopposed shoulder portions.

5. A method according to claim 4 wherein the opposite edges of saidstrip are formed to retreat from said opposed shoulder portions towardsaid front face and terminate within the opening between said flangeportions.

1. A method of forming an elongated structural element comprisingfeeding a continuous strip of sheet material in a longitudinal path ofmovement, progressively bending said strip inwardly from the sidesthereof to form a continuous length of structural element having a bodyportion of generally rectangular cross section comprising a pair ofgenerally parallel front and rear faces connected by side faces, and apair of generally parallel flanges extending outwardly from said frontface away from said rear face.
 2. The method of claim 1 wherein saidstrip also is formed to provide a channel having a restricted inletopening disposed within said body portion.
 3. A method according toclaim 1 including notching transverse grooves in said continuous stripof sheet material at predetermined longitudinally spaced intervalstherealong prior to bending said strip, and severing said continuouslength of structural element after forming the same at said grooves intodiscrete structural elements.
 4. A method of forming an elongatedstructural element comprising feeding a continuous strip of sheetmaterial in a longitudinal path of movement, progressively bending saidstrip inwardly from the sides thereof to form a continuous length ofstructural element having a body portion of generally rectangular crosssection comprising a pair of generally parallel front and rear facesconnected by side faces, and a pair of generally parallel laterallyspaced flanges extending outwardly from said front face away from saidrear face, said flanges being folded over at the outer ends thereof toprovide cam surfaces leading to opposed shoulder portions.
 5. A methodaccording to claim 4 wherein the opposite edges of said strip are formedto retreat from said opposed shoulder portions toward said front faceand terminate within the opening between said flange portions.